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X31F Part 1: Early Progress

In part 0, I discuss the inspiration and background for this model. Sunshine Models had produced a resin kit of the Pennsylvania X31F, but the owner has retired, and the kits are no longer in production. Fortunately, Bowser produces a model in styrene – a medium more modelers are comfortable working with.

Breaking news: David Sieber writes to tell me “One happy bit of info:  Sunshine Models is still active and Martin Lofton has not retired from the resin kit business (though last year, his wife Tricia shared that he had been considering it due to health problems).  However, all PRR X31-series kits were retired from his line due to sales plummeting after Bowser came out with their X31s.  This has happened with several of his resin offerings after various manufacturers have brought out a plastic version.  You can still get other unique cars like Pennsy X37 and X41 boxcars, B&O M-55C and H boxcars, and many others from Sunshine; see Jim Hayes’ unofficial Sunshine website at http://www.sunshinekits.com/ - Sunshine themselves are not online.  If you order, be prepared to wait at least 6 months for your order to be filled, since except for newly issued cars produced for the few shows that Sunshine attends, everything is cast to order and they are just that backlogged with orders.”

Perhaps the biggest problem with this model is the underframe. The model has four stringers instead of two, and the center sill is greatly simplified.

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The X31Fs were rebuilt with four stringers instead of two starting in 1954. The problem is these stringers went the entire length of the car, eliminating the diagonal braces outside of the bolster. So, either the diagonal brace has to go, and the four stringers extended to the ends of the car, or the four stringers have to go, and replaced by two. Since I wanted the model to represent a car in 1953, this eliminated the option of building the car with four stringers.

So I carefully milled the underframe to eliminate the four stringers, and the mounting holes for the brake gear that Bowser had included. I also milled away the coupler pockets to make way for the scale sized draft gear from Accurail. I carefully chiseled and sanded away the parts I couldn’t mill, and then rescribed the wood plank flooring. I also puttied the brake mounting holes.

Construction began moving from the floor up (down, but inverted). The first thing I did was add the stringers. The prototype stringer is a Z-angle with the open face toward the center sill. This goes under all the frame crossbearers, which was impractical on the one-piece floor, so I had to do it in sections between the crossbearers. The Z-angle was simulated by two pieces of Evergreen styrene – a 0.030″ square piece, with a 0.010″ x 0.030″ strip for the flange portion that mounts to the floor. A pair of calipers came in handy to measure the distance between each crossbearer, and cut the styrene to length.

When this was done, attention was turned to the Brake Pipe. So far, this has been only added between the bolsters, but will eventually extend to the end of the car to mate up to the air hoses. This will be T-ed off to the triple valve and other brake parts at a later date. Although I’ve done this in the past with brass wire, I was encouraged to try 0.020″ Plastruct Styrene Rod, and I really like how this works.

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Attention was then turned to the center sill. The model has just a vertical rib with rivets on the end, while the prototype has two I-beams, spaced 12″ between the top flange. I filed off the rivets, and cut 0.020″ x 0.060″ styrene strips to fit between the bolsters and each of the larger crossbearers. Those crossbearers, as near as I can tell, have straps that fit over the center sill, so rather than sand them flush with the top of what becomes the I-beam web of the center sill, I just put the top flange between them.

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I have also been working on the body. There was a large casting blob on the roof. Although it would be mostly hidden by the roofwalk, I decided that since the model will encourage close scrutiny, I would do my best to remove it. The bodywork was completed with a coat of Gunze-Sangyo Mr. Surfacer 1000 (don’t you just love Japanese product names?) thinned with MEK.

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In part 2, I’ll continue to work on the brake rigging of the underframe, and describe some of the work I’m doing to the body.

X31F Part 0: Introducing the Pennsylvania Railroad X31F Box Car

What’s an SP modeler doing modeling a Pennsylvania freight car? And an oddball car at that? Rest assured, I’ve not turned into a Slobbering Pennsy Freak (SPF for short). However, freight car rosters should reflect the time and place you want to depict, and the sheer number of Pennsylvania freight cars that were around, even on the Southern Pacific coast line, means you can’t ignore the Pennsy.

“Mat25315″ is an HO scale modeler from the Czech Republic who posted this awesome video. That third car in the train really caught my eye, though. I asked, and he told me it was a Bowser Pennsylvania Railroad X31F 40 foot box car, so I had to learn more.

X31F? OK, I’d heard of the X29 – In the early 1920′s the Pennsylvania Railroad developed plans for a steel-sheathed box car and designated the design X29. Production of this design began in 1924 and lasted into 1934. During this time period almost thirty thousand Pennsylvania X29 cars were built. Then came the X30 box car, but it was a one-off experimental box car who’s design was not repeated. One car – PRR 59861 – built in 1931. It was a whopping 70’ 6” in length with only two 6 foot Youngstown doors on each side. It is a unique car built for the Pennsy for the transport of newly manufactured hook-and-ladder fire-engines from the American LaFrance factory in Elkhart, Indiana to whatever municipality ordered one. Pennsy went back to more pedestrian 40 foot boxcars after that.

Pushing the capacity vs. clearance issue in the post WWI era, the Pennsy sought to improve the interior capacity of the X29 design by incorporating a rounded roof. Auto parts and finished automobiles became more important in the 1920s, culminating in the X31 which first appeared in 1931. This allowed for a 10’ interior height in a car that could still be interchanged with smaller railroads. By 1936, the single and double door X31A (with a 10’ 5” interior height) had replaced the X29 as the general service box car. This was followed by the X31B and X31C double door 40 footer.

X31Fs were rebuilt from double door X31As in 1943 for the express purpose of moving Jeeps (although they were also used to handle the movement of auto parts). I found this kind of interesting, as it parallels Southern Pacific’s rebuilding of 89’ flat cars to haul Chevy Vegas nearly 30 years later – a purpose built automobile car! Only the center part of the roof was raised, presumably due to the angled loading of the Jeeps. So the X31F could be seen just about anywhere delivering Jeeps to dealers nationwide.

It didn’t take me long to find out this and other X31 boxcars were a project of the PRRPro Yahoo Group, so there was a lot of information readily available, and some very helpful modelers who tolerated my ignorant questions and comments. I’d like to take the opportunity to thank some of them:

Bruce Smith, owner of the group
Steve Hoxie
Greg Martin
Robert Putt
Elden Gatwood for supplying key drawings to the group

Thanks guys!

Southern Pacific C-30-1 Caboose – Part 1

I started work on some Southern Pacific C-30-1 cabooses a couple weeks ago. The Southern Pacific (and it’s subsidiaries) had more cabooses of this class than any other class. It’s a mandatory model for anyone modeling the Steam or Steam-Diesel transition era, and I didn’t have any. For more information, please see Tony Thompson’s blog, or better yet, his book, Southern Pacific Freight Cars, Volume 2: Cabooses.

These started out as Walthers models, which were disassembled, stripped of their paint and lettering (using 91% Isopropyl Alcohol, followed by a run through my sand blast booth), at which point the model is, essentially, and undecorated kit.

First thing I wanted to do was to paint the interior. The cabooses were originally simply varnished. Later on, the interior received green paint. I have yet to find a color photograph of the interior, but I have found a Proto:48 scale model (“O-scale” but to a much higher level of precision than what most know and see as “O-scale”). My only issue with Bob’s model is that I don’t think the interior should be “Sea Foam Green,” but a bit darker shade.

The interior is going to be difficult to see through the windows, so I didn’t go to nearly as much detail as Bob did, but here’s what I did:

Paint used was P-B-L Star Brand Interior Green and Wood, with Tamiya Gloss Black for the upholstered cushions.

Next, I turned my attention to the underframe, and getting rid of those oversize coupler pockets. Most HO coupler pockets are, by NMRA recommended practice (RP-22), 1/4″ wide. This scales out to about 24 inches. Most real coupler pockets are 18″, so the coupler pockets are 33% too big, or, suitable for S-scale. With today’s scale size couplers, that’s just not acceptable anymore. In fact, since we’ve had scale size couplers (for about the last 15 years), it’s only exacerbated the out of scale proportions of the NMRA coupler pocket.

Fortunately we have an alternative. Unfortunately, it’s a difficult retrofit. Accurail offers a scale size coupler box for it’s Accumate scale size couplers. However, most modelers do not like plastic couplers because, at least early on, they were quite problematic when compared to metal couplers. Fortunately, we now have metal scale couplers by Sergent Engineering that not only overcome this issue, but a number of other issues with model couplers, such as exposed spring mechanisms. But you can read up more on those couplers at the Sergent Engineering site.

Another complaint with the Walthers car is that the coupler box extends out too far. Comparing with drawings in Thompson’s Caboose book, it is a few thousandths off, but easily correctable once the new coupler box is installed.

I used my mill to remove the necessary material from the center sill and end platform casting:

Some flash from the milling operation remains, and will be cleaned up with a file. Here’s another photograph showing the same part with one that’s unmolested:

Now, I know what you may be thinking – How are the couplers going to be mounted? Won’t you have to put a screw into the end platform?

Stay tuned for part 2, where I tackle the coupler mounting issue.

“Have You Used Your Mill Yet?”

 


A friend of mine asked – Have you used your mill yet? The answer is Yes!

I built a fixture to hold N-scale locomotive shells so that I can drill accurate holes for various wire detail parts, like grab irons (sometimes called Hand Holds), and lift rings (much like an eye bolt). This fixture holds the shell in several orientations, including at an angle matching the angle of the hood ends, so that the holes can be drilled perpendicular to the ends.

 

 

Palatka Railfest 2011

Today I went to the Palatka Railfest, held at the Amtrak depot in Palatka, Florida. Despite two of my friends bailing out on joining me, I had a great time!

There were a few vendors of the major scales – N, HO, and O scale. There were some very impressive HOn3 models on display from Blackstone Models, and this line is very impressive! Two vendors had Digital Command Control (DCC) systems, and a third was selling just DCC decoders. They were all very helpful in answering my questions about DCC systems, and I came very close to buying one!

Alas, one of the HO scale vendors packed up and left early – less than an hour after the show started! Must have been some sort of politics involved, as it certainly wasn’t because he had sold all his wares.

The museum at the depot has two HO scale layouts. The first one you see is a triple-decker layout, where you basically only see the top layer, and a window into the second layer down. What surprised me was that they were planning on constructing two more layers above the current top deck!

Bachmann 80-Ton class C shay

Athearn FEC GP40-2

The second layout is built against a wall with trains from about knee height up to the ceiling, depicting the side of a mountain. Several loops allow multiple trains to run in and out of several vignettes, and many of these vignettes include animated scenes. From blinking lights on a large communication tower, to pigeons circling the roof of a building, to a highway bridge being constructed with a crane, the layout captivates visitors.

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There was a G-scale layout setup outside with several loops of track. This was nicknamed the “Railroadeo.” But the highlight of the show, for me, was the N scale modular layout that the Ocala Model Railroads Historic Preservation Society came with. Here are some photographs:

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I’m not a big fan of cars with graffiti on them, but it’s a sign of the times. The Tropicana Juice Train, which runs from Florida to New Jersey just about every day, had a couple of them, though, and I have to admit, I really like them! Take a look:

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Thanks for looking!

Vacation in Cusick, WA

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Anna and I are vacationing in her home town, Cusick, WA. Many people wonder, why Cusick? Sometimes I wonder, too. But sometimes, a picture is worth a thousand words. Oh, and being in cattle country, the beef is excellent!

Mini-Mill Part 3: DRO Completed

Mill Setup

Well, the Digital Readout is finally finished on my mill, and it works well. I still have to figure out how to use it, and make sure that the direction of the axis make sense. This thing is really a small computer.

Two projects remain on the mill. First, I need a chip guard to protect the X-axis scale at the back of the table. Next, I’ve devised an LED lighting system that needs to be installed. I’m using two LED ring lights around the spindle to help illuminate my work. I just need some adhesive backed magnetic material to secure the light to the body of the mill.

It’s Alive!

This is the bare board for my Shumatech DRO-550 Digital Read Out, for use with my mill.

It came mostly assembled, but may parts still had to be soldered on. I have to finalize the case construction. A case was purchased from Wildhorse Innovations, but the back isn’t available drilled for the connectors I’m using for my iGaging scales. The scales already had a digital remote readout, but I like how this is going to allow all three scales in one location, with a single interface.

Water Pump

Nearly two weeks ago, my engine overheated. I pulled off to the side of the road immediately to avoid damage to the motor. Opening the hood, I knew it was bad – there was no steam rising from the engine. I carefully removed the “radiator cap” (which is located on the coolant bottle, and not on the radiator), and the system was bone dry.

I called a friend to ask them to bring water. It poured out the bottom as fast as I poured it in. Not a good sign. It was getting dark and stormy, and all I could see was the water was comming out from below. I suspected the lower radiator hose had ruptured. I couldn’t move the car on my own, and it was turning into a dark and stormy night, so instead of having the car towed home, I decided to have it towed to Pep Boys, the only repair shop that was open. They also have a convenient arrangment with towing companies.

Why does the name Pep Boys remind me of hyperactive juviniles?

They diagnosed the problem as a failed water pump, and handed me an estimate for over $1000. That was too much for me. I was figuring on replacing a lower radiator hose and getting on with my evening, but they had other plans.

The water pump is driven by the (cam) timing belt. I’d replaced the two of them at 105,000 miles – the factory recommended service interval for the belt. So I’d done the job already, and was familiar with what it took to get it done. I bought a water pump, timing belt, and a timing belt tensioner pulley, and left the car overnight, as I couldn’t arrange for a tow truck anymore that night.

The next morning, another friend gave me a ride back to Pep Boys, and I arranged to have the car towed home. Disassembly went fairly fast, aided by a pneumatic ratchet wrench. By lunch time, the car was at “parade rest” (see photo above).

Reassembly is always more difficult. With this job, the challenge is to get the cam timing correct. The belt tensioner is also a bit of a pain. The belt tensioner is a hydraulic device, that pushes on that new pulley I bought. It has to be compressed and pinned. The pin is relatively small, though, and the tensioner tends to destroy the pin. I’ve used allen wrenches, and drill bits, and both will be destroyed in the process, bent or broken.

As the tensioner takes up the slack on the belt, it tends to move, disturbing the carefull alignment. You have to anticipate how the belt will move when tensioned, and compensate. And if you get it wrong, the computer will see the misalignment between the cam position sensor and the crank position sensor, and fail to allow the engine to start. This is probably a good thing, but it’s frustrating to diagnose. I got lucky this time.

Reassembly went fine, although I did have to reinstall the timing belt and tensioner twice to get things to line up the way they are supposed to. Then came time to add water, and it poured out as fast as it went in. Did I just replace the water pump for nothing?

This time I could see the water gushing from the side of the engine. Near the Thermostat housing where the lower radiator hose connects. I felt around, and it seemed like I had attached the lower radiator hose OK. It’s really hard to see that area. From the front, it’s blocked by the alternator. From underneath, it’s blocked by the oil filter. From up top and rear, it’s blocked by the exhaust manifold. So I removed the alternator for better access, put back the lower radiator hose, and filled with water.

No leaks! Evidently, I failed to get the lower radiator hose on correctly. Maintenance induced error. I put everything back together a final time, filled with water, and still no leaks. Good. Drove around with water in the cooling system for a few days just to make sure, then drained and filled with coolant (it seems a little rediculous to talk about antifreeze in Florida, but it lubricates things like the water pump, and keeps things from rusting, so it is necessary).

It’s been just over a week, and the car has worked fine. No overheating. No coolant leaks.  Success!

Mini Mill Part 2

 

Well, I have just about set up the Mini Mill the way I like want it. I have installed iGaging scales on all three axis in preparation for a real Digital Readout system. The remote readout nearly gives me this already, something I’ve come to call “The Ghetto DRO.” These remote readout scales cost me about $120, and installation was the most challenging thing. I used the mill to construct some of the parts used to mount the scales, so this gave me some practice.

The next step will be construction of the Shumatech DRO-550. I’ve bought all the parts needed to complete the construction from Wildhorse Innovations. All that’s needed is to fire up the soldering iron, and get started. Which reminds me. I got tired of using the cheap Weller soldering iron clones that Radio Shack sells. They’ve served me and my father well, but things have improved now, especially with the introduction of lead free solders. I’ve really wanted to get a temperature controlled solder station, so I ordered one. More later, when it arrives. Others have had more problems than me, but my chief complaint is how fast the tip corrodes and erodes. It will also be nice to have a real holder for the soldering iron, and not rely on the coffee can (don’t laugh – my father the EE used the same thing!)

Unfortunately, the table on my mini mill started to rust. This isn’t surprising, given Florida’s hummidity. I scrubbed the rust off with oil and a green Scotch-Brite pad, followed by polishing with some Mothers Billet Polish, and then protected the table with a coat of good old Carnuba paste wax. Home Depot also had a sale on a dehumidifier, so that now sits below my mill’s work bench. The bucket filled with water overnight, so I hooked up some tubing to run outside the garage. This should help ALL my tools from rusting. It should also make working in the shop a lot more bearable in the hot summer months.